Method and apparatus for preparing release paper rolls of adhesive insulation material and release paper rolls of adhesive insulation material which are stackable and non-adherent to each other

ABSTRACT

A method and apparatus is disclosed for preparing release paper rolls of adhesive duct insulation material which are stackable and non-adherent to each other. The adhesive insulation material contemplated is the type used for sealing crevices and spaces in air cooling and leaking systems generally referred to as “Heating, Ventilation and Cooling” systems, or “HVAC”. The apparatus and method disclosed dispenses strips ( 16 ) of the adhesive insulation material onto release paper ( 20 ) generally silicone coated on at least one side, leaving a marginal tab ( 30 ) which is then bent upwardly to contact each alternate side face ( 32 ) of the insulation strips ( 16 ) to protect them from adhering to each other when placed in a shipping container. This system thus avoids the need for inserting a sheet of interface paper between the rolls to prevent them from sticking to each other.

CROSS REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application No.62/170,000, filed Jun. 2, 2015, which is hereby incorporated byreference.

BACKGROUND OF THE INVENTION 1. Field of the Invention

The present invention relates to a novel method and apparatus forpreparing release paper rolls of adhesive insulation material andrelease paper rolls of adhesive insulation material which are stackableand non-adherent to each other.

2. Description of the Prior Art

Air conditioning and heating systems, generally referred to as Heating,Ventilating and Cooling (i.e., HVAC) systems, generally include anetwork of pathways for the treated air, which pathways are generallyformed by a network of ducts, attached to each other.

The ducts are generally fastened together to form continuous airways.While the present day the attachment techniques for the ducts attempt toprovide seals which are mechanically leakproof, the seams and spaces ofthe ductwork often need to be sealed by application of a suitablesealant material.

In order to prevent leakage at the seams between ductwork sections, andat any junctions vulnerable to air leakage, a soft pliable and stickyadhesive material is used to seal the potential leaks. This material isgenerally referred to as duct seal, duct sealant, adhesive insulationmaterial and the like. The material has a relatively soft and pliableconsistency and is readily worked into open seams and crevices toprevent leaks.

Present day packaging of this type of duct sealant generally dispensesmultiple parallel strips of the duct sealant onto a silicone releasepaper. Thereafter, the release paper is cut immediately below each sideof the strip of duct sealant and the combined duct sealant and releasepaper is rolled into rolls of predetermined size. The rolls are thendeposited into a shipping container.

Since the exposed sides of the duct sealant will generally contact eachother, when packaging the rolls in a shipping container, it is generallynecessary to place a sheet of paper between adjacent rolls to preventthe rolls from sticking to each other. The sheet of paper may be singlecoated or double side coated with silicone.

The present invention is directed to a method of preparing such releasepaper rolls by adhesive duct sealant which can be packaged in adjacentcontracting relation without fear of the rolls becoming stuck to eachother. In particular, each roll is provided with a marginal tab ofrelease paper on at least one side of the duct sealant, which marginaltab prevents the roll of duct sealant from sticking to the next roll.

SUMMARY OF THE INVENTION

The present invention relates to a method and apparatus for preparingrelease paper rolls of adhesive duct sealant material which have amarginal tab of “excess” release paper on at least one side of the ductsealant, which marginal tab is bent upwardly to prevent the roll of ductsealant from sticking to the next roll when placed in a shippingcontainer. This configuration avoids the need to place a sheet of paper(release type or other) between adjacent rolls in the shipping containerto prevent the rolls from sticking to each other.

Accordingly, the added expanse of the additional sheets of release paperand the labor to place the sheets of release paper between adjacentrolls it thereby avoided. The invention also relates to the improvedcombined insulation material and release paper rolls which are producedon the apparatus and according to the method.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred embodiments are described hereinbelow with reference to thedrawings, wherein:

FIG. 1A is a schematic representation of the first stage of the methodof preparing release paper rolls of adhesive insulation material (i.e.,referred to as “Duct Seal” or the like), and release paper rolls ofadhesive insulation material which are stackable and non-adherent toeach other, according to the invention;

FIG. 1B is a schematic representation of the second stage of the methodaccording to the invention, showing the steps of compressing the rollstogether, and then depositing them into a container for shipment;

FIG. 2 is an elevational view, taken along lines 2-2 of FIG. 1A, showingthe step of depositing the insulation material on the release paper;

FIG. 3 is an elevational view, taken along lines 3-3 of FIG. 1A, showingthe initial cuts to create strips of release paper having the insulationmaterial positioned thereon;

FIG. 4 is a plan view, taken along lines 4-4 of FIG. 3, viewing thecutter blades used to create the strips of release paper with a marginalportion adjacent each row of insulation material;

FIG. 5 is a partial cross-sectional view, taken along lines 5-5 of FIG.1A, showing a “paddle wheel” type of rotating blades which make axiallyextending spaced slits in the marginal portions of the release paper tofacilitate ease of rolling of the combined insulation material andrelease paper into “ready to use” rolls, with minimal wrinkling orcrumpling of the release paper when portions adjacent the slits overlapeach other;

FIG. 6 is a view taken along lines 6-6 of FIG. 5, partially incross-section, and illustrating the axially extending spaced slits madein the marginal portions of the release paper adjacent respectiveadjacent strips of insulation material;

FIG. 7 is a partial cross-sectional view, taken along lines 7-7 of FIG.1A, showing the tab folding guides used to fold the marginal portions ofrelease paper gradually and upwardly until they become engaged inface-to-face relation with the side walls of the strip of insulationmaterial as will be shown in FIG. 8;

FIG. 8 is a cross-sectional view, taken along lines 8-8 of FIG. 1A,showing the strips of insulation material having upwardly foldedmarginal tabs of the release paper which protect the respective sidesurfaces of the strips of insulation material when stacked together in acontainer;

FIG. 9 is a cross-sectional view, taken along lines 9-9 of FIG. 1A,showing three representative rolls of combined release paper andinsulation material, said rolls positioned in lateral spaced relationbefore being “united” together in lateral face-to-face engaged relationfor packing, as shown in FIG. 1B;

FIG. 10 is an elevational view, taken along lines 10-10 of FIG. 1B,showing a hydraulic system which includes a hydraulic cylinder andrelated linkage, which are arranged to “unite” the rolls of insulationmaterial as shown in FIG. 1B, into a compact arrangement for depositinginto a packing container for shipment and ultimate use;

FIG. 11 is an elevational view, taken along lines 11-11 of FIG. 1B,showing the rolls of insulation material in a united and compact mode,and being deposited into a packing container for shipment;

FIG. 12 is a cross-sectional view, taken along lines 12-12 of FIG. 11,showing the finished rolls of combined insulation material and releasepaper positioned in the packing container for shipment, and illustratingthe release paper marginal tabs positioned between the respective rollsof insulation material, which marginal tabs prevent the rolls fromadhering to each other until they are ultimately used in insulationsystems;

FIG. 13 is a plan view of an alternative embodiment of the cuttersystem, which embodiment produces lateral “V-shaped” cuts in themarginal tab portions of release paper to better facilitate folding ofthe release paper with less wrinkling, when the combined insulationmaterial and release paper is wrapped to form rolls, as shown in theprevious FIGS.;

FIG. 14 is perspective view of a portion of three representativefinished rolls of combined insulation material and release paperproduced according to the invention, utilizing the “V-shaped” cuttingsystem of FIG. 13;

FIG. 15 is a fragmentary plan view of yet another alternative embodimentof the cutter system of FIGS. 5 and 13, in which the system of providinglateral cuts in the release paper is eliminated, thereby facilitatingrolling of the insulation material and release paper into rolls havingthe marginal tab portions of release paper positioned in an overlappingmode, with some portions being wrinkled or crumpled in overlappingfolds; and

FIG. 16 is a perspective view, similar to FIG. 14, showing a portion ofthree representative rolls of insulation material produced according tothe system of FIG. 15, i.e., without the use of lateral cutters, showingthe marginal portions of release paper folded in overlapping relation.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring initially to FIG. 1A, there is shown a schematicrepresentation of the first stage 10 of the method of preparing releasepaper rolls of adhesive insulation material that are stackable andnon-adherent to each other, according to the present invention.

In FIG. 1A the advancement of the strips of duct sealant and releasepaper, before and after being combined, is provided by a system ofdistinct pairs of rollers 11, 13, 15, each roller of each pair beingrotated in respectively opposite rotational directions as shown by thearrows in FIG. 1A. These pairs of rollers provide the forward momentumwhich advances the strips of insulation and release paper, as will bedescribed hereinbelow.

In FIG. 1A, the system 10 includes a roll 12 of insulation material,commonly referred to as “duct sealant”, “duct seal”, or the like. Theduct sealant is a soft and pliable material generally used in Heating,Ventilation and Cooling (i.e., HVAC) systems, as well as by utilities toseal unwanted spaces and potential water leaks. The duct sealant has a“putty-like” consistency, which is capable of being molded by hand intoany shape required to effect an air-tight and water-tight seal within anopen space. This duct sealant has a soft “sticky” consistency similar towindow putty or children's “Play-doh”.

The roll 12 of insulation material includes a plurality of distinctaxially spaced rolls 14 of the duct sealant material 16, and is mountedabove a roll 18 which simultaneously dispenses release paper 20. Roll 12deposits multiple parallel strips of the sealant material 16 onto therelease paper 20 as it is fed into the system, as shown in FIG. 1A andFIG. 2.

As noted, and as shown in FIG. 2, the roll 12 is comprised of aplurality axially spaced rolls 14 of such duct sealant material,dispensing continuous strips 16 of the duct sealant material, whichstrips 16 are simultaneously deposited on the release paper 20 as eachroll 14 of duct sealant unwinds in the counterclockwise direction, andas the roll 18 of release paper unwinds in the clockwise directiondispensing release paper 20, as shown in FIGS. 1A and 2.

The release paper 20 of roll 18 is comprised of a durable thin sheet ofpaper, suitably coated with release material such as silicone on oneside, to promote temporary and releasable adherence of the insulationmaterial to the coated side of the paper for storage purposes prior touse. Release paper having two coated sides can be used, as well.

In FIG. 2, the spaced strips 16 of insulation material are deposited onthe release paper 20 as shown. Each strip 16 of duct sealant material isseparated from the next adjacent strip 16 by spacer rollers 22, leavinga predetermined marginal “tab” portion 24 of release paper between eachadjacent pair of spaced apart duct sealant strips 16.

Referring now to FIG. 3, a system of rotating cutter blades 26 arepositioned in spaced relation, to cut the release paper immediatelyadjacent side surface 28 of each strip of duct sealant, as shown. Thiscut leaves a free marginal strip (or tab) 30 of release paper attachedto the release paper underneath the next adjacent strip of insulationmaterial, such that the marginal tab 30 can subsequently be foldedupwardly to meet the opposite adjacent side 32 of the next adjacentstrip of duct sealant as shown and as will be described. It is importantto note that each blade 26 is spaced and arranged to cut the releasepaper 20 immediately adjacent the same corresponding sides of adjacentstrips 16 of duct sealant, so that each “left over,” or “excess”marginal tab 30 of release paper is free to be folded upwardly inface-to-face relation with the side surface of the next opposing strip16 of duct sealant, as shown in FIGS. 3 and 7.

The cutter blades 26 are seen in cross-section in FIG. 4 during theirrotational movement, which cuts the release paper 20 immediatelyadjacent the side surface 28 of each respective strip 16 of duct sealantmaterial. Referring again to FIG. 1A, after cutting the release paper 20at station 3-3, as seen in FIGS. 3 and 4, the combined release paper andinsulation material proceeds to the next station 5-5 in which “paddlewheel”-type cutter 31 having rotating cutter blades 34, is operative toprovide a series of longitudinally spaced lateral cuts 36 in themarginal tabs 30 of release paper between the strips 16 of insulationmaterial. The operation of paddle wheel cutter blades 34 is best viewedin FIGS. 5 and 6, whereby the rotating cutter blades 34 providelaterally spaced axial cuts 36 in the marginal tabs 26 of release paper,positioned between adjacent strips 14 of insulation material.

The lateral cuts 36 in the marginal tabs 30 of release paper facilitaterelative ease of rolling the combined insulation strip 16 and releasepaper 20 into convenient rolls by permitting the marginal tabs 30 ofrelease paper to be wrapped into roll form without significant portionsof the tab 30 of release paper being wrinkled or “crumpled”. Inparticular, while portions of the release paper may neatly overlapadjacent portions, bulky wrinkles are avoided in this embodiment.However, it is noted that while such relatively bulky wrinkles may beavoided in this embodiment, in some instances, in an alternativeembodiment to be described hereinbelow, wrinkling of the marginal tabportions may be permissible.

The next step in the procedure is to guide the marginal tabs 30 upwardlyfrom the unfolded position shown in FIG. 3, to the upwardly foldedpositions shown in FIG. 8, until the marginal tabs 30 are fully foldedupwardly and in face-to-face contact with the side surfaces of thestrips 24 of the insulation material strips 14.

This folding procedure is accomplished at station 7-7 by tab foldingguides 38, best shown in FIG. 1A and FIG. 7. Tab guides 38 areconfigured as curved metal or plastic guides which are engaged by themoving marginal tabs 30 of release paper whereby the release paper tabs30 are gradually folded upwardly toward the side surfaces 28 of thestrips 16 of insulation material, as the combined insulation materialstrip 16 and release paper 20 progresses forwardly toward the rollingstation, while supported on support platen 40.

FIG. 1B is a schematic representation of the second stage of the methodaccording to the invention, showing the steps of compressing the rollstogether by the hydraulic cylinder 46 and gripping linkage 48 to form acombined roll 43, and then lifting the combined roll 43 and transformingit to be deposited in shipping container 56.

FIG. 8 is a cross-sectional view of three representative strips 16 ofinsulation material protected on the bottom by release paper 20 and onone side surface by a marginal tab 30 of release paper. As shown,marginal tabs 30 of release paper are folded upwardly sufficient toengage the respective alternate side surfaces 28 of the strips 16 ofinsulation material.

Referring to FIG. 9, there is shown a cross-sectional view taken alonglines 9-9 of FIG. 1 A, of three representative rolls 42 of combinedinsulation material 16 and release paper 20, with one respective sidesurface 28 of each strip 16 of insulation material of each roll beingprotected by the upwardly folded marginal tab 30 of release paper. Theserolls 42 may then be merged together for packaging, without thepossibility of adjacent rolls becoming stuck to each other, due to theprotective effect of the marginal tabs 30 of release paper on therespective alternate sides of the strips of insulation material.

Referring now to FIG. 10, there is illustrated a hydraulic system 44,including a hydraulic cylinder 46 and related “clamp-type” linkage 48which is arranged to grip the rolls 42 of combined insulation material16 and release paper 20, together to the relative positions shown inFIG. 11, i.e., ready for packaging in shipping container 50, shown inFIG. 11. The clamp-type linkage 48 includes extendable link 50 havingattached at either end gripping plates 52, 54 which are movable axiallyas the hydraulic cylinder is actuated between the extended and thewithdrawn positions. Thus, gripping plates 52, 54 are first movableoutwardly and then inwardly toward the rolls 42 of combined insulationmaterial 16 and release paper 20 until it “compresses” the rolls towardeach other to form combined 43, whereby the axial dimension is reducedsufficiently to fit the combined rolls into a packing container 56 asshown in FIG. 11.

The clamp-type linkage 48 includes extendable link 51 having attached ateither end, gripping plates 52, 54, which are movable axially as thehydraulic cylinder is actuated between the extended and the withdrawnpositions. Thus, gripping plates 52, 54, are first movable outwardly andthen inwardly toward the rolls 42 of combined insulation material 16 andrelease paper 20 until it “compresses” the rolls 43 toward each otheruntil the axial dimension is reduced sufficiently to fit the combinedrolls into a packing container 56 as shown in FIG. 11.

FIG. 12 shows a cross-sectional view, taken along lines 12-12 of FIG.11, of the finished rolls 42 of combined insulation material 16 andrelease paper 20 deposited into container 56 by gripping plates 52, 54of the gripping linkage 48.

FIG. 13 illustrates an alternative embodiment of the invention wherebythe system of providing straight axial cuts in the release paper isreplaced by a “paddle-wheel” type system of V-shaped cutting blades 58which provide V-shaped cuts 60 in spaced relation, similar to the device34 of FIG. 1A, but modified to include V-shaped cutter blades 58 asshown.

This system facilitates folding the finished product, i.e., insulationstrip 16 and release paper 20, more evenly, with less wrinkling orcrumpling of the portions of release paper which become overlapped inthe rolling procedure, as shown in FIG. 14. In particular, the V-shapedcuts result in removal of the “V-shaped” material, thereby permittingthe marginal tabs of release paper to be rolled into roll form withoutsignificant wrinkling or crumpling.

FIG. 15 illustrates yet another alternative embodiment of the presentinvention, wherein the step of providing lateral cuts in the marginaltabs of the release paper is eliminated. Thus in this embodiment, thestrips of combined insulation material 16 and release paper 20 may bewrapped into roll form, with the excess portions of the marginal tabs ofrelease paper being wrinkled or crumpled as shown at 61 in FIG. 16,which in some instances may be permissible.

In this embodiment, however, the primary objective of the presentinvention is nevertheless satisfied, in that the side surfaces 28 of therolled strips 16 of insulation material are protected from sticking tothe next adjacent roll, as in the previous embodiments.

Furthermore, in this embodiment, wrinkling or crumpling may betolerated, particularly where there are no constraints on the size ofthe shipping container which permits the combined stack of rolls ofinsulation material and release paper to be larger than the size of theshipping container used for the previous embodiments.

LIST OF REFERENCES

-   10 First Stage of the Method of Preparing Release Paper Rolls-   10 System-   11,13,15 System of Distinct Pairs of Rollers-   12 Roll of Strips of Insulation Material-   14 Axially Spaced Rolls of Insulation Sealant Material-   16 Duct Sealant Strip-   18 Roll of Release Paper-   20 Release Paper-   22 Spacer Rollers-   24 Predetermined Marginal “tab” portion of release paper-   26 Rotating Cutter Blades-   28 Side Surface of Strip of Insulation-   30 Marginal Strip, or “Tab” of Release Paper-   31 Paddle-Wheel Type Cutter-   32 Opposite Adjacent Side of the Next Adjacent Strip of Duct Sealant-   34 Paddle Wheel Cutter Blades-   36 Laterally Spaced Axial Cuts-   38 Tab Folding Guides-   40 Support Platen-   42 Three Representative Rolls of Combined Insulation Material and    Release Paper-   43 Combined Rolls-   44 Hydraulic System-   46 Hydraulic Cylinder-   48 “Clamp-Type” Linkage-   50 Shipping Container-   51 Extendable Link-   52,54 Gripping Plates-   56 Shipping Container-   58 V-shaped Cutting Blades-   60 V-shaped Cuts-   61 Excess Portions of the Marginal Tabs of Release Paper Wrinkled or    Crumpled

1. A method for preparing release paper rolls of adhesive insulationmaterial, which comprises: a) dispensing a sheet of release paper havinga release coating on at least one side; b) simultaneously dispensing aplurality of strips of a relatively soft pliable adhesive duct sealantmaterial onto said release paper; c) cutting said release paperimmediately below and along the same corresponding side of eachalternate strip of duct sealant, so as to produce a marginal tab ofexcess release paper attached to one side of each said adhesive strips;d) rolling said strips of combined insulation material and release paperinto roll form; and e) cutting said combined strips of insulationmaterial and release paper at a predetermined length so as to produce aroll of predetermined size, while said marginal tabs of release paperbecome folded to provide an interface for the side surface of each saidroll of insulation material; and f) bringing said rolls of combinedinsulation material and release paper together so as to contact eachother, with each said marginal tab of release paper providing aninterface between adjacent rolls of insulation material.
 2. The methodaccording to claim 1, further comprising depositing said combined rollsof insulation material and release paper into a container for shipmentfor use by an end user.
 3. A roll of strips of insulation material onrelease paper, including a marginal tab of release paper folded upwardlyto provide a protective interface for one side surface of said roll ofinsulation material, such that a plurality of such rolls may be placedin face-to-face contacting relation without fear of said rolls becomingstuck to each other, due to the protective effect of said marginal tabof release paper between adjacent rolls.
 4. Apparatus for producing aroll of combined strips of insulation material and release paper, whichcomprises: a) a dispensing roll for dispensing a continuous sheet ofrelease paper coated on at least one side; b) a dispensing roll forsimultaneously depositing strips of durable insulation material ontosaid release paper; c) a plurality of cutting devices for cutting saidrelease paper immediately adjacent each said strip of insulationmaterial to form a marginal tab of release paper associated with eachsaid strip; d) a guide for folding said marginal tab of each said stripupwardly to contact the same corresponding side surface of each saidstrip; e) a device for rolling said combined strips of insulationmaterial and release paper into a roll form; and f) a device forbringing said combined strips of insulation material and release papertogether with an axial direction and for depositing said combined rollinto a shipping container.
 5. A roll of strips of insulation material onrelease paper, each said strip having a marginal tab of release paperfolded upwardly on one side to protect said strip from sticking to anext adjacent strip when packaged in a shipping container.